Thesis

Miniaturised experimental simulation of ingot-to-billet conversion

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Awarding institution
  • University of Strathclyde
Date of award
  • 2024
Thesis identifier
  • T16991
Person Identifier (Local)
  • 201970846
Qualification Level
Qualification Name
Department, School or Faculty
Abstract
  • Ingot-to-billet conversion processing, one process of which is known as “cogging”, is an important production step in high-value metallurgical manufacturing. It is necessary to homogenise and refine the microstructure of high-performance alloys before they proceed to subsequent processing stages. Despite its importance, the process is still not very well understood for many modern advanced alloys and few published studies exist. The limited knowledge of the deformation and microstructure evolution leads to difficulties in achieving the desired accuracy in microstructural control. Traditional uni-axial testing is not fully representative of the forging processes seen in industry, and does not capture different elements of open-die forging parameters. Given significant costs of large multi-tonne workpiece ingots and the difficulties with their non-destructive evaluation, it is crucial to develop a laboratory-scale evaluation for the cogging process so that scrapping and re-processing can be avoided. The “Micro Future Forge” has been developed as a reproducible laboratory-scale experimental method for exploring the various thermo-mechanical process mechanisms of hot open die forging. This novel methodology employs a purpose-built apparatus, that has been designed to be cost-effective and portable. The test set-up uses a remotely operated manipulator assembly constructed predominantly from standard off-the-shelf components in conjunction with a conventional uni-axial load frame. This combination allows for high operational scalability. Multi-directional open-die forging (cogging) of single and dual-phase alloys has been successfully accomplished using the described apparatus, demonstrating an ability to attain the desired beneficial refinement of the microstructure. Application of this experimental approach provides precisely controlled conditions and allows high research specimen throughput to discover new insights into the structural transformations that occur in industry-scale forgings, while offering savings in energy, material, time and capital investment. The obtained experimental data can be used for thermo-mechanical process optimisation of high-performance alloys, guiding larger scale testing and manufacturing trials (e.g., AFRC Catapult Future Forge), as well as informing the development of digital-twins for various high-value metallurgical manufacturing processes.
Advisor / supervisor
  • Vorontsov, Vassili A.
Resource Type
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